Volvo 940 Tailgate repair clips

The tailgate panels of the 700 and 900 series often suffer from cracked mounting points.
I decided to come up with a neat way to fix this.

I've design a few parts that can be printed on a 3D printer. Make sure you use ABS of ASA material. PLA is not temperature resistant enough and will melt on hot summer days!
There a various ways you can do the repair with these parts:

If you still have the original (90 degree turning) clips, you only need to print the brackets.
If you don't have these clips, you can use screws or bolts and print some additional parts.
  
 

• The printed inserts have to be M4 tapped, use a 25mm M4 bolt (M5 will not work, M3 will probable strip the treads too easily)
  When using bolts, you need the extra washer on top and the (optional) big washer at the bottom
• The bracket can be glued to the broken panel for an "invisible repair" look. (looks completely stock!)
• You can also drill two holes and use self tapping screws or bolts from M3 to M5.
  M3 is probably too weak. I designed the bracket for M4, but in the end I tapped M5 threads and used two M5 bolts because thats what I had laying around.

Mounting is pretty straight forward.
You have to file the broken tab flush with the panel, or even better, file down an extra 2mm so the new tab will be in exactly the same position.
Hold the new bracket in place, if the edge of the panel and barcket is in a straight line, then you're ready to glue to bracket or carefully drill two holes from the inside out.
(of course, When using M4 bolts, dril 4mm holes and tap a M4 thread in the bracket)
    
If you don't have the original clips anymore, tap a M4 thread in the printed replacement clips and just press them in the original holes in the metal tailgate.

Now it is time to hang the tailgate panel back on the 4 tabs at the window side.

With the brackets mounted, use the original clips to secure the panel.
If you're using M4 bolts, use the extra washer (make sure the small side pops into the bigger hole in the bracket) and before crewing it down, you can use an optional big washer for a flush mounting look (this washer falls over the rectangular clip)
After that, remount the plastic bar with the two big screws on the center of the panel and click the plastic bezel back into place. 

More info / photos on : https://940.winand.nl/tailgate.html